Systems, methods and apparatuses for magnetic processing of solar modules

ABSTRACT

Provided herein are methods, apparatuses and systems for fabricating photovoltaic cells and modules. In certain embodiments, the methods, apparatuses and systems involve coating ferromagnetic substrates with thin film solar cell materials and using magnetic force to constrain, move or otherwise manipulate partially fabricated cells or modules. According to various embodiments, the methods, apparatuses and systems provide magnetically actuated handling throughout a photovoltaic cell or module fabrication process, from forming photovoltaic cell layers on a substrate to packaging the module for transport and installation. The magnetically manipulated processing provides advantages over conventional photovoltaic module processing operations, including fewer mechanical components, greater control over placement and tolerances, and ease of handling. As a result, the methods, apparatuses and systems provide highly efficient, low maintenance photovoltaic module fabrication processes.

BACKGROUND OF THE INVENTION

Photovoltaic cells are widely used for generation of electricity, withmultiple photovoltaic cells interconnected in module assemblies. Suchmodules may in turn be arranged in arrays and integrated into buildingstructures or otherwise assembled to convert solar energy intoelectricity by the photovoltaic effect.

Certain photovoltaic cell fabrication processes involve depositing thinfilm materials on a substrate to form a light absorbing layer sandwichedbetween electrical contact layers. The front or top contact is atransparent and conductive layer for current collection and lightenhancement, the light absorbing layer is a semiconductor material, andthe back contact is a conductive layer to provide electrical currentthroughout the cell.

In one example of a fabrication process, a metallic back electricalcontact layer is deposited on a substrate. A p-type semiconductor layeris then deposited on the back contact electrical contact layer and ann-type semiconductor layer is deposited on the p-type semiconductorlayer to complete a p-n junction. Any suitable semiconductor materials,such as CIGS, CIS, CdTe, CdS, ZnS, ZnO, amorphous silicon,polycrystalline silicon, etc. may be used for these layers. A toptransparent electrode layer is then deposited on the p-n junction. Thislayer may be a conductive oxide or other conductive film and is used forcurrent collection. Once these or other materials have been deposited onthe substrate to form a photovoltaic stack, the substrate and thin filmmaterials deposited on it are cut into cells. Multiple cells are thenassembled into a solar module.

SUMMARY OF THE INVENTION

Provided herein are methods, apparatuses and systems for fabricatingphotovoltaic cells and modules. In certain embodiments, the methods,apparatuses and systems involve coating ferromagnetic substrates withthin film solar cell materials and using magnetic force to constrain,move or otherwise manipulate partially fabricated cells or modules.According to various embodiments, the methods, apparatuses and systemsprovide magnetically actuated handling throughout a photovoltaic cell ormodule fabrication process, from forming photovoltaic cell layers on asubstrate to packaging the module for transport and installation. Themagnetically manipulated processing provides advantages overconventional photovoltaic module processing operations, including fewermechanical components, greater control over placement and tolerances,and ease of handling. As a result, the methods, apparatuses and systemsprovide highly efficient, low maintenance photovoltaic modulefabrication processes.

One aspect of the invention relates to a method of fabricating a thinfilm photovoltaic solar module involving providing a plurality of thinfilm photovoltaic solar module components, at least one of saidcomponents being magnetic; providing processing apparatus for thin filmphotovoltaic solar module fabrication, said apparatus comprising one ormore magnetic actuators; and fabricating the thin film photovoltaicsolar module by a process that comprises magnetically manipulating themagnetic module components with the one or more magnetic actuators.

In certain embodiments, the magnetic module component or componentsincludes a ferromagnetic substrate on which thin film photovoltaic cellmaterials are coated. The magnetic module components may be any or allof wholly or partially fabricated thin film photovoltaic cells. Incertain embodiments, the ferromagnetic substrate is a ferromagneticstainless steel foil, e.g., a series 400 stainless steel foil, having athickness of at least 1 mil, or in certain embodiments, at least 2 mils.

The magnetic actuators act on the magnetic module components byattractive or repulsive magnetic force to move, constrain, secure,align, transfer or otherwise manipulate magnetic module components.Examples of magnetic actuators include component alignment mechanisms,component securing mechanisms, magnetic pallets and component grabbers.

According to certain embodiments, the method involves transferring apartially fabricated thin film solar module between a plurality ofprocessing stations using magnetic manipulation of module components.Also in certain embodiments, the method involves at least one of thefollowing operations, one or more which involve magnetic manipulation ofthe ferromagnetic substrate: a coating operation to coat thin filmmaterials on a ferromagnetic substrate; one or more cutting operationsto cut the ferromagnetic substrate to form cells; a first laminatingoperation to laminate the cells; a wiring operation to provideconductive cell interconnections; a positioning operation to positionthe laminated cells on a module substrate; and a second laminatingoperation to laminate the module substrate having cells positionedthereon. Other operations that may involve magnetic manipulationincluding testing and sorting wholly or partially fabricated thin filmsolar cells and assembling bussing, diodes and other components of asolar module during fabrication.

Another aspect of the invention relates to a method of fabricating amodule of thin film photovoltaic cells, including providing a partiallyfabricated thin film photovoltaic cell module, said partially fabricatedmodule comprising one or more magnetic elements; and magneticallymanipulating at least some of the one or more of the magnetic elementsto thereby fabricate the module.

Another aspect of the invention relates to a system for fabricating thinfilm photovoltaic solar modules having a plurality of thin filmphotovoltaic solar module components. The system includes a plurality ofprocessing stations for fabricating thin film photovoltaic solarmodules; a plurality of transport devices for transferring partiallyfabricated thin film photovoltaic solar modules between processingstations; and one or more magnetic actuators, each actuator associatedwith a processing station or a transfer device, and configured tomagnetically manipulate at least some of the module components.

Examples of magnetic actuators include a magnetic pallet, e.g.,associated with a solar cell positioning station, a bussing positioningstation, a diode positioning station, a laminate stack assembly station,or other stations; an alignment mechanism, e.g., associated with a solarmodule component station, a solar module component positioning station,or other stations; a component grabber, e.g., associated with a solarmodule component positioning station, a testing station, a sortingstation, a wiring station, a laminating station or other stations; acomponent securer, e.g., associated with a coating station, a cuttingstation, an alignment station, a positioning station, etc.

According to various embodiments, the plurality of processing stationsincludes one or more of the following: a thin film web coating stationto deposit thin film materials on a stainless steel substrate, one ormore cutting stations to cut the stainless steel substrate to formcells, one or more laminating stations to laminate the cells andmodules; a testing station to test cells, a sorting station to sortcells based on performance, an aligning station to align components, anda positioning station to position the laminated cells on a modulesubstrate.

According to various embodiments, the transport devices may includeconveyor belts and component grabbers including robots having endeffectors configured to handle components. In certain embodiments,conveyor belts and assembly line transport devices configured to supportmagnetic pallets are provided.

Another aspect of the invention relates to a method of fabricating amodule of thin film photovoltaic cells, the method including a coatingoperation to coat thin film materials on a ferromagnetic substrate; oneor more cutting operations to cut the ferromagnetic substrate to formcells or modules; a module assembly operation to assembly a modulepre-laminate stack including a module substrate having cells positionedthereon, bussing, diodes and module encapsulation materials; and alaminating operation to laminate the module pre-laminate stack; whereinat least one of the operations or transfer there-between comprisesmagnetic manipulation of the ferromagnetic substrate.

The method may include monolithic interconnection or non-monolithicinterconnection of the photovoltaic cells. In certain embodiments, themethod further includes a first laminating operation to laminatephotovoltaic cells or cell-width strips. This laminating operation mayinvolve providing a magnetic force to secure the cells or cell-widthstrips, e.g., during feeding the components into the laminator.

In certain embodiments, the method includes a positioning operation toposition photovoltaic cells on a module substrate. The positioningoperation or other operations may involve aligning a module componentprior to or as part of the operation. In certain embodiments, aligningthe cell involves magnetically actuating cell placement under a positionsensing device. In certain embodiments, the positioning operationcomprises providing a magnetic pallet to support a partially fabricatedthin film photovoltaic cell module, placing a plate on the pallet, andafter placing the plate on the pallet, positioning a plurality of thinfilm photovoltaic cells on the plate.

The method may further involve transporting a pallet having a plate andphotovoltaic cells thereon for further processing; wherein the pluralityof thin film photovoltaic cells are immobilized on the plate by themagnetic field during transport. In certain embodiments, the coatingoperation comprises providing a magnetic force to secure a roll ofstainless steel while coating the roll with the thin film materials. Themagnetic force may secure a vertical roll of stainless steel.

These and other aspects of the invention are described further belowwith reference to the figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates one example of a system for fabricating solar modulesusing magnetic actuators according to certain embodiments.

FIG. 2 is a schematic illustration of a magnetic substrate having thinfilms deposited thereon prior to and after being cut according tocertain embodiments.

FIG. 3 illustrates another example of a system for fabricating solarmodules using magnetic actuators according to certain embodiments.

FIG. 4 is a schematic illustration of a solar cell and wiring forinterconnection with other solar cells according to certain embodiments.

FIG. 5 is a schematic illustration of an apparatus including a magneticactuator for securing a web of magnetic material during a solar modulefabrication process according to certain embodiments.

FIG. 6 is a schematic illustration of an apparatus including a magneticactuator for cutting magnetic substrate/thin film stack during a solarmodule fabrication process according to certain embodiments.

FIGS. 7A and 7B are schematic illustrations of aligning a magneticmodule component during a solar module fabrication process usingapparatuses including magnetic actuators according to certainembodiments.

FIG. 8 presents schematic illustrations of apparatuses includingmagnetic actuators for aligning and positioning magnetic solar modulecomponents during a solar module fabrication process according tocertain embodiments.

FIG. 9 is schematically illustrates an alignment/positioning stationincluding a magnetic actuator and a module substrate having magneticsolar cells positioned thereon according to certain embodiments.

FIG. 10 schematically illustrates picking up and placing a magnet modulecomponent during a solar module fabrication process using a transferapparatus including a magnetic actuator according to certainembodiments.

FIG. 11 presents schematic illustrations of apparatuses includingmagnetic actuators for securing magnetic module components during solarmodule fabrication processes according to certain embodiments.

FIG. 12 is one example of a sample flow process diagram showing a solarmodule fabrication process using magnetic manipulation according tocertain embodiments.

FIG. 13 is a schematic illustration of a module assembly according tocertain embodiments.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Reference will now be made in detail to specific embodiments of theinvention. Examples of the specific embodiments are illustrated in theaccompanying drawings. While the invention will be described inconjunction with these specific embodiments, it will be understood thatit is not intended to limit the invention to such specific embodiments.On the contrary, it is intended to cover alternatives, modifications,and equivalents as may be included within the spirit and scope of theinvention. In the following description, numerous specific details areset forth in order to provide a thorough understanding of the presentinvention. The present invention may be practiced without some or all ofthese specific details. In other instances, well known mechanicalapparatuses and/or process operations have not been described in detailin order not to unnecessarily obscure the present invention.

Provided herein are methods, apparatuses and systems for fabricatingphotovoltaic cells and modules. In certain embodiments, the methods,apparatuses and systems involve coating ferromagnetic substrates withthin film solar cell materials and using magnetic force to constrain,move or otherwise manipulate partially fabricated cells or modules.According to various embodiments, the methods, apparatuses and systemsprovide magnetically actuated handling throughout a photovoltaic cell ormodule fabrication process, from forming photovoltaic cell layers on asubstrate to packaging the module for transport and installation. Themagnetically manipulated processing provides advantages overconventional photovoltaic module processing operations, including fewermechanical components, greater control over placement and tolerances,and ease of handling. As a result, the methods, apparatuses and systemsprovide highly efficient, low maintenance photovoltaic modulefabrication processes.

The methods, apparatuses and systems described herein may be used withnon-monolithic interconnection processing schemes, in which individualcells are fabricated and strung together, and monolithic interconnectionprocessing schemes in which interconnections are made between cellsdirectly on the substrate, e.g., during thin film deposition.

The following terms are used throughout the specification. Thedescriptions are provided to assist in understanding the specification,but do not necessarily limit the scope of the invention.

Magnetic actuators: Magnetic actuators refer to apparatuses thatincluding one or more magnetic elements configured to magneticallymanipulate a magnetic module component. The magnetic elements canpermanent magnets, electromagnets, ferromagnetic materials, etc. Inparticular embodiments, the magnetic actuators include a permanentmagnet. According to various embodiments, the magnetic elements may bestationary or movable.

Magnetic manipulation: Magnetic manipulation refers to the use ofmagnetic force to move, constrain, position, align, transfer orotherwise manipulate a magnetic module component such as a magneticsubstrate. According to various embodiments, the magnetic force may bethe primary force manipulating the module component or it may be used inconjunction with another mechanism or force. The magnetic force actingon the magnetic module component may be attractive or repulsive.

Magnetic module components: Magnetic module components refer to modulecomponents that include a magnetic material and that may be magneticallymanipulated during fabrication of photovoltaic cells and modules. Incertain embodiments, the magnetic module components includeferromagnetic materials. According to various embodiments, some or allof the magnetic module components are integral to the completed module.Examples of magnetic module components include any or all of webs orsheets of a magnetic substrate material, webs or sheets of a magneticsubstrate having thin film deposition materials deposited thereon,partially or wholly defined unconnected cells, including cells and cellwidth strips, magnetic substrates having monolithically ornon-monolithically interconnected solar cells thereon, etc. According tovarious embodiments, the module components may laminated or unlaminated,wired or unwired, etc.

Magnetic substrate: In certain embodiments, the magnetic modulecomponent is a magnetic substrate on which photovoltaic materials aredeposited or otherwise formed. In certain embodiments, the magneticsubstrate is a ferromagnetic material. In particular examples, themagnetic substrate is a ferromagnetic stainless steel foil. Series 400alloys may be used in particular embodiments. Other alloys that may beused include series 500 and 600 alloys. For most embodiments, series 300stainless steel does not exhibit the requisite ferromagnetism to be usedin accordance with the methods described herein. Series 300 stainless isweakly ferromagnetic, but becomes non-magnetic when heated totemperatures used in many solar module processes. The magneticsubstrates used with the embodiments described herein are thick enoughto be easily magnetically manipulated. According to various embodiments,the magnetic substrate is at least about 1 mil thick, and in certainembodiments, at least about 2 mils thick.

FIG. 1 is a block diagram showing various elements of an example of amagnetically-actuated solar module processing system. At 110 is a thinfilm deposition coater or coaters, in which thin film materials, whichmay include light absorbing materials as well as back and top contactlayers, are deposited or otherwise coated on a magnetic substrate.

FIG. 2 shows a perspective view 215 of an example of a magneticsubstrate 201 supporting thin films 203, 205, 207 and 209. For thepurposes of illustration, the figure is not to scale; for example,thickness of the magnetic substrate may be on the order of mils thethickness of the thin film stack on the order of microns (or hundredthsof mils) with the x- and y-dimensions of the substrate on the order offeet. Substrate 201 includes a magnetic material, e.g., a thinferromagnetic foil. As indicated, in various embodiments of theinvention, the substrate 201 is relatively thin, such as for example,between about 2-100, or in certain embodiments, 2-10 mils. However,other suitable thicknesses may also be used, e.g., 50 mils. Backelectrical contact layer 203 provides electrical contact to allowelectrical current to flow through the photovoltaic cell, and may bemade of any appropriate material, e.g., molybdenum, niobium, copper,silver, etc. A p-type semiconductor layer 205 is deposited on backelectrical contact layer 203 and an n-type semiconductor layer 207 isdeposited on p-type semiconductor layer 205 to complete a pit junction.According to various embodiments, any suitable semiconductor materials,such as CIGS, CIS, CdTe, CdS, ZnS, ZnO, amorphous silicon,polycrystalline silicon, etc. are used for layers 205 and 207. Forexample, the p-type semiconductor layer 205 may be CIGS or CIS, and then-type semiconductor layer 207 may be CdS or a cadmium free materialsuch as ZnS, ZnO, etc. Top transparent electrode layer 209 is depositedon the p-n junction. 1n certain embodiments, top transparent electrodelayer 209 is a transparent conducting oxide (TCO), for example, zincoxide, aluminum-doped zinc oxide and indium tin oxide. FIG. 2 shows anexample of a thin film stack on a magnetic substrate; other materialsmay be used in addition to or instead of any of these materials to formsolar cells using the methods, apparatuses and systems described herein.

Returning to FIG. 1, according to various embodiments, the depositioncoaters 110 are configured to deposit the thin film materials on rollsor webs of substrate material. As described further below, in certainembodiments, deposition of thin film materials include magneticmanipulators to secure a roll or web of substrate material prior toand/or during deposition.

After deposition, the magnetic substrate having thin films depositedthereon is transferred to cutter or slitter 120 where it may be cut in avariety of manners to wholly or partially define cells or a module. FIG.2 shows an example of a sheet of a magnetic substrate 201 having thinfilms deposited thereon slit into cell-width strips 217. In certainembodiments wherein monolithic interconnection is employed, the cells onsubstrate 201 are interconnected prior to any cutting operation. Inthese embodiments, the substrate having thin films deposited thereon maybe cut to partially or wholly define a solar module. As describedfurther below, a cutter may employ one or more magnetic actuators,

A wirer 130 may be employed to provide electrical connections to thecells, e.g., for later interconnection between cells. In certainsituations, e.g., where monolithic interconnection is employed, a wirermay not be present. A wirer may employ one or more magnetic actuators.

Cell positioner 140 positions individual cells including magneticsubstrates and thin film solar cell materials on a module substrate. Forexample, in certain embodiments cells are positioned on a glasssubstrate that protects the interconnected solar cells and other modulecomponents from environmental conditions. In embodiments that employmonolithically interconnected cells, this component is typically notused.

Module laminator 150 encapsulates the solar cells and other modulecomponents between front and back encapsulating layers that protect theinterconnected solar cells and other module components fromenvironmental conditions. According to various embodiments, the frontand back layers be rigid or flexible materials. In a particular example,the front layer is a rigid transparent material such as glass and theback layer is a weatherable material such as polyvinyl fluoride. Asnoted above, in certain embodiments, a cell positioner positionsindividual cells on a front or back layer prior to lamination.

According to various embodiments, one or more of the system componentsdescribed above includes one or more magnetic actuators. In certainembodiments, the system includes components to transfer magnetic modulecomponents. In certain embodiments, additional system componentsincluding but not limited to web IV testers, cell testers, diode and buspositioners also include one or magnetic actuators.

FIG. 3 shows another example of a block diagram showing various elementsof an example of a solar module processing system. In this example,slitter 320 may be used to form cell-width strips of a magneticsubstrate/thin film stack after being transferred from thin filmdeposition chambers 310. The cell width strips may then be transferredto a wirer 330, which applies an electrically conductive wire or otherelectrically conductive material to collect current from a cell and/orprovide electrical contacts for interconnection with other cells. Incertain embodiments, the conductor is applied to an insulating carrier,which acts as a substrate during deposition of the conductor. Theconductor may be a metal wire, such as copper, aluminum, and/or theiralloy wires, which may be supported by or attached to the carrier. Thewirer applies the electrically conductive material such that it contactsone or more electrodes of the cells or strips, and in certainembodiments, provides points of contact. Like other system components,wirer 330 may have a location and functionality that varies based onsystem implementation. For example, in certain embodiments, the wirer330 may receive cells after having been cut, or prior to being slit intostrips. In certain systems, the cells may be laminated after a wire orother conductive material is applied, or in other systems, the cells orconductive material may not be laminated at all.

The cell-width strips, including conductive material may be fed to acutter 334, which cuts the strips along a transverse axis to definecells. FIG. 4 shows a schematic of an example of a cell 410 includingconductive wire 470 applied to the top conductive layer of the cell 410.Conductive wire 420 provides current collection and electrical contactpoints for interconnection with other cells. As indicated above, acarrier material or laminate (not shown) may be attached to theconductive wire 420. The laminate may also overlay the top conductivelayer and/or other components of solar cell 410.

Returning to FIG. 3, after being cut, the cells may then be transferredto sorter 336, which tests and sort each cell based on its performance,e.g., with only cells having a threshold efficiency or output beingassembled into a module. The system may further include a cellpositioner 340 as described above with respect to FIG. 1. Bussing anddiode positioner(s) 342 may also be included in the system. Additionalsub-systems or stations to position or assemble additional components ofthe module prior to module lamination may be included as is a modulelaminator 350 as described above with respect to FIG. 1.

According to various embodiments, one or more of the system componentsdescribed above includes one or more magnetic actuators. For example, incertain embodiments, cell width strips of magnetic materials are fedinto a wirer using a magnetic actuator. In certain embodiments, thesystem includes components to transfer magnetic module components. Incertain embodiments, additional system components including but notlimited to web IV testers, cell testers, cell sorters, diode and buspositioners and other components also include one or magnetic actuators.

Magnetic actuators and apparatuses including magnetic actuators includebut are not limited to module component alignment mechanisms, modulecomponent securing mechanisms, module component positioning mechanisms,module component grabbers and transport devices, each of which may beassociated with any of the various processing stations used to fabricatethin film photovoltaic modules. According to various embodiments, modulecomponent alignment mechanisms include an alignment area on which thecomponent to be aligned is placed and a magnetic element to facilitatealignment. In certain embodiments, alignment involves detecting theposition of the component and transmitting position correctioninformation to a component handler. Further details of examples ofmagnetic actuators and processes involving magnetic manipulation ofphotovoltaic module components are described below. The methods,apparatuses and systems of the invention are not limited to theseparticular examples.

In certain embodiments, thin film deposition involves coating a roll orweb of ferromagnetic substrate material with the thin films, e.g., byphysical vapor deposition (PVD), chemical vapor deposition (CVD),electroplating, or other types of coating or deposition processes. Incertain embodiments, the thin film deposition coaters include one ormore magnetic actuators to secure a web. FIG. 5 shows an example of arotatable roller 510 and a stationary magnetic actuator 520 positionedadjacent to the roller 510. During thin film coating, a web offerromagnetic substrate (not shown) is fed through the thin film coaterby one or more rollers 510. Magnetic actuator 520, including one or moremagnets, is positioned behind roller 510 such that its magnetic fieldsecures the web flush against the roller 510 as it is fed through thecoating apparatus. The roller and magnetic actuator may be oriented inany direction; in particular embodiments, the roller 510 and magneticactuator 520 are vertically oriented. According to various embodiments,the roller 510 may or may not include a ferromagnetic or magnetizablematerial to contribute to the magnetic field strength.

The roller and magnetic actuator described above may be implemented notjust in the thin film coaters but at any point in the process in which aroll or web of a magnetic substrate material is transferred or processedon a roller, including pre or post-coating operations.

FIG. 6 shows an example of a slitter apparatus 601 that includes one ormore magnetic actuators. A magnetic substrate 603 having a film stackthereon is fed to the slitter by in-feed 605. The in-feed 605 andslitting apparatus may be configured for various substrate sizes.Substrate 603 may of any width, e.g., between about 0.3 m and 3 m, e.g.,1 m, though other sizes may be used as appropriate. In certainembodiments, magnetic substrate 603 is fed into the slitter afteremerging from a thin film deposition coater. According to variousembodiments, the substrate 603 may be on a roll or web, or may be in fedinto the slitter 601 as a discrete sheet. For example, in one processingscheme, thin film materials are deposited on a vertical web of stainlesssteel foil, with transverse cuts then made to form sheets of the steelsubstrate/film prior to being fed into the slitter. The unwound roll orsheet may be supported by a support (not shown) while being fed intoslitter 601. Slitter 601 includes two rotating cylinders, between whichmagnetic substrate 603 is fed: upper cylinder 607 and lower cylinder609. In certain embodiments, magnetic substrate 603 is continuously fedinto the slitter, rotating blades on or more of the cylinders cut thesubstrate into strips as the substrate is moved through the slitter 601by the rotating cylinders. The resulting strips exit the slitter viaout-feed 611. One or more magnetic actuators 614 is positioned underout-feed 611 to prevent strips from flying up after emerging from theslitter and wrapping around the upper cylinder 607. In certainembodiments, magnetic actuator 614 eliminates the need for a knockdownbar to keep strips down. In certain embodiments of a slitterincorporating a magnetic actuators the out-feed may be made of amagnetic or magnetizable material in addition to or in lieu of a magnetpositioned below it. A magnetic actuator may also be positioned under oradjacent to the in-feed 605 to align or secure the incoming magneticsubstrate.

According to various embodiments, a slitter incorporating a magneticactuator to prevent post-slitting fly away of strips (or other sizedpieces) of a magnetic substrate or other magnetic module components isnot limited to the particular slitting apparatus depicted. For example,a magnetic actuator may be incorporated into any slitting apparatus tosecure the slit pieces.

Additional component securing, mechanisms may be employed through outthe solar fabrication processes described herein. The mechanisms mayinclude a member against which a module component is to be secured aswell as a magnetic element located in proximity to the member such thatits magnetic field secures the component against the member. In certainembodiments, securing a component involves preventing or reducingmovement away from the member in one or more directions.

In certain embodiments, the magnetic actuators align or positionmagnetic components. FIG. 7A shows an example of such an apparatus inwhich a solar cell 707 including thin film materials on a magneticsubstrate is aligned. At 721, a cell 707 is placed at a receiving areanext to an aligning mechanism, including magnet 703 and fence 705, e.g.,by conveyor, robot placement, etc. In certain embodiments, magnet 703 islaterally movable from a position away from fence 705 to an alignmentposition adjacent to fence 705. Fence 705 may be made of a non-magneticmaterial such as aluminum or other metals, ceramics, etc. At 721, magnet703 is at a position away from fence 705 and cell 707 is not aligned. At723, magnet 703 is moved into an alignment position flush against bar orfence 705. The attractive magnetic force exerted by magnet 703 onmagnetic substrate of cell 707 moves cell 707 into aligned contact withfence 705. At 725, magnet is moved away from fence 705. Aligned cell 707is free to be moved to testing or other processing. FIG. 7 b shows a topview of cell 707 b being aligned in an example process sequence. Afterwiring, lamination and cutting, cell 707 b is placed at an alignmentstation including fence 705 and magnetic actuator 703 as indicated at751. Previously aligned cell 707 a is at a testing station. Magneticactuator 703 is moved into an alignment position as indicated at 753,and the length of cell 707 b is aligned along fence 705. Now aligned,cell 707 b is moved to a testing station as indicated at 755, where itis tested prior to being sorted based on the test results. Newly cutcell 707 c is moved into the alignment station.

The magnetically actuated alignment mechanisms and process sequencesdescribed above are examples of magnetically actuated alignmentapparatuses and process sequences within the scope of the invention. Incertain embodiments, for example, a magnetically actuated alignmentmechanism may include a stationary magnet, though as indicated, incertain embodiments, decreasing the magnetic force acting on the alignedpartially fabricated module component prior to moving it may bedesirable in certain applications. Moreover, magnetically actuatedalignment mechanisms may be employed in other places in a solar modulefabrication process, e.g., to align a magnetic web prior to or duringthin film deposition, to align a sheet prior to or during cutting, toalign a strip or individual cells prior to or during wiring, to aligncells prior to positioning on a module substrate, etc. FIG. 8 showsadditional examples of magnetically actuated alignment mechanisms. Thesemechanisms may be employed, e.g., with a cell positioner or othersub-system.

Alignment station 801 includes magnetic actuator 803 to secure and/orfacilitate alignment of magnetic component 805. In one example, magneticcomponent 805 is a solar cell including a magnetic substrate. Themagnetic component 805 is dropped or otherwise placed onto a receivingarea above magnet 805. In certain examples, a robot may be employed toplace solar cells or other magnetic components on the receiving area.According to various embodiments, the magnetic force provided by magnet805 may snap the magnetic module component into place at the receivingarea. In certain embodiments, this may be sufficient to align thecomponent, e.g., for subsequent pick-up by a robot. In otherembodiments, a position detector such as optical detector 807 may beused to detect the precise position and provide position correctioninformation if necessary to a robot for subsequent positioning on amodule substrate.

In certain processes, cells are positioned in particular patterns on asubstrate to connect them in parallel or parallel-series circuits.Positioning may be done on a cell by cell basis or in certainembodiments, an alignment or positioning station may be configured toposition multiple cells on a module substrate simultaneously. Acomponent of a magnetically actuated alignment or positioning sub-systemis shown at 811. Multiple cells 815 having magnetic substrates are fedonto receiving areas 814. Each receiving area is magnetized, e.g., madewith a magnetic material or having a magnet thereunder, such that eachcell snaps into place on its respective receiving area when fed. Incertain embodiments, the receiving areas are sized and positioned tocorrespond with the desired placement on a module substrate. A side view817 of component 811 is also shown, with receiving areas 814 and magnets813 depicted. The cells are fed to the receiving areas 814 such thateach cell slots into a receiving area, aligned and positioned forpick-up. In certain embodiments, position correction information may bedetermined using an optical detector as well. FIG. 9 is a schematicillustrating cells 903 at an alignment station 911. Once aligned usingmagnetic manipulation as described above, the magnetic cells may bepositioned on a module substrate 921. In certain embodiments, a robotpicks all or multiple cells 903 simultaneously and positions all ormultiple cells 903 on module substrate 921 simultaneously. In certainembodiments, once cells are positioned on a module substrate, they aresecured via magnetic force to ensure proper placement of bussing orother connection materials.

Transfer of magnetic module components and partially fabricated modulesmay also be implemented using magnetic manipulation and systemcomponents having magnetic actuators. In certain embodiments, robots mayuse magnetic force to transfer magnetic module components. FIG. 10 showsan example of a robot end effector 1005 including magnet 1001. Magnet1001 is movable in relation to end effector 1005 between a pick positionand a place position. Although not shown, the magnet may be connected toa pneumatic or other actuator to move between positions. In the pickposition indicated at 1007, the magnetic force is strong enough, to pickup and transfer magnetic component 1003 to its desired location. In theplace position indicated 1009, the magnet is moved away from themagnetic component 1003, reducing the magnetic force on the magneticcomponent and allowing placement at the desired location. Robotmanipulation of magnetic components is not limited to pick and placemoves, but may use magnetic force to transfer or otherwise manipulatemagnetic module components. In certain embodiments, electromagnets maybe employed, e.g., instead of the movable magnet shown in FIG. 10 toalternate between pick and place configurations.

In certain embodiments, magnetic pallets are provided. The magneticpallets may be used to secure magnetic components during module assemblyas well as for transfer operations. FIG. 11 shows a schematic ofmagnetic pallet 1100 including one or more magnetic elements 1101. Inthe example shown in FIG. 11, magnetic elements 1101 are spaced apartstrips. As with the magnetic elements of other system components, themagnetic elements 1101 may take various forms and arrangements,including a single magnetic plate, etc. In certain embodiments, strips1101 have a constant polarities along their lengths, i.e., such that thetop surface of each strip has a single polarity (N or S). Magnetic fielddirection of adjacent strips is alternated in certain embodiments (N S NS, etc.) to improve total field strength felt by the cells or othermagnetic module components. In certain embodiments, the pallet 1100includes fixtures 1113 on the underside of the pallet 1100 to accuratelyposition and locate the pallet 1100 on assembly stations on an assemblyline. The pallet may also have a thin magnetic sheet 1105 under themagnetic elements to improve magnetic field strength. In certainembodiments, a ferromagnetic sheet, e.g., a stainless steel sheet isused. Stainless sheets of between about 10-100 mils, e.g., 20 mils maybe used in particular examples. In certain embodiments, the magneticstrengths exerted on the solar cells or other components at least 0.5 N.

A solar cell 1103 on the pallet 1100 is shown. In use, a magnetic pallet1100 may support a module substrate on which solar cells are to bepositioned. The module substrate may be a front or back substrate of theeventual completed module. In certain examples, the module substrate isa transparent material such as glass. A side view 1111 of a pallet 1100supporting a glass substrate 1107 on which solar cells 1103 arepositioned is depicted. Magnetic elements 1101 secure solar cells 1103in their positions. In certain embodiments, a module substrate such asthat depicted in FIG. 9 is supported by a magnetic pallet during a cellpositioning operation. In certain embodiments, a polymeric sheet isplaced on the glass substrate prior to cell placement.

Magnetic pallet 1100 may include a base 1109 made out a light, sturdymaterial such as a polymer or other appropriate material. In certainembodiments, solar cells are placed perpendicular to the magneticelements 1101, such that each solar cell spans multiple magneticelements. An example of a magnetic pallet arrangement includesPlastiform® 1530 magnet material (1.4 MCOe) strips, rectangular in topprofile and having dimensions of 0.5″×0.3″ (w×h) spaced about 1.5″apart, such that 7 strips span a 12.3″ solar cell on a 20 mil steelplate.

In certain embodiments, the magnetic elements of the magnetic palletsare raised on a pallet body or steel plate; for example, magneticelements in 1101 in FIG. 11 are raised features on steel plate 1105. Incertain embodiments, the magnetic pallet may also include material inbetween these elements to form a planar surface on which a modulesubstrate may rest. For example, the magnetic pallet may include asilicone or polyurethane material or other high friction polymericmaterial that interlocks with the magnets of the pallet.

The magnetic pallet secures cells post placement and ensures properplacement of bussing or other connection material. In certainembodiments, this eliminates the need for elaborate fixturing oradhesives that add cost and additional assembly requirements. Inaddition, during the assembly process, the module may traverse along aconveyor or other means of transport. The magnet pallet secures thecells to prevent movement during transport, which can lead to issuesduring and post lamination. In addition, in certain embodiments, thedownward force created by the cells helps hold the lamination materialin place during the assembly process. In certain embodiments, apolymeric sheet is placed on the glass substrate prior to cellplacement.

FIG. 12 is a process flow diagram describing certain operations in amagnetically actuated process of fabricating solar modules according tocertain embodiments. At 1210, thin film materials are deposited aferromagnetic substrate forming a thin film stack including lightabsorbing material and top and bottom contact layers. In an example, thesubstrate is a series 400 stainless steel substrate having a thicknessof 0.5-50 mils, e.g., 0.5-10 mils. Solar cells are then fabricated fromthe ferromagnetic substrate and thin film stack in an operation 1220.According to various embodiments, fabricating solar cells may involveany or all of wiring, laminating and cutting operations to produceindividually manipulatable ferromagnetic solar cells, e.g., ofdimensions of around 12.3″×1.3″. Solar cells of any dimension may befabricated. The solar cells are then tested and sorted to remove solarcells having an efficiency or output of below a certain threshold in anoperation 1230. A module is assembled including ferromagnetic solarcells in an operation 1240. Additional module components are alsoassembled, e.g., including bussing and diodes. In certain embodiments,wiring or otherwise interconnecting the solar cells of a module may takeplace at this operation, rather than operation 1220. In certainembodiments, one or more encapsulating layers may also be added to theassembly. FIG. 13 shows an example of various components of apre-laminate module assembly that may be formed, including magneticsolar cells 1308. Interconnections between the cells, bussing and diodesare not shown. The solar cells 1308 are encapsulated by layers 1310,which may be a thermoplastic material, e.g., an acrylic or siliconematerial that protects the solar cells. A material 1314 surrounds solarcells 1308, and in this example, is embedded within encapsulating layers1310. The material 1314 prevents moisture its incursion layers 1310. Inone example, a butyl-rubber containing moisture getter or desiccant isused. The encapsulated cells 1308 are protected by a transparent frontlayer 1312 and back sheet 1302. Back sheet 1302 protects the solar cellsfrom environmental conditions and may include a moisture barrier 1304,e.g., a rigid or flexible material such as glass or metal, an insulationsheet 1305, e.g., an insulative polymer material such as polyethyleneterpthalate (PET) and weatherable back layer 1306, such as afluoropolymer material. The module assembly including ferromagneticsolar cells is laminated in an operation 1250. At 1260 variouspost-lamination processes, including attaching junction boxes, moduletesting, etc. may then be performed to complete fabrication.

According to various embodiments, the presence and order of variousoperations may vary. For example, in the case of process incorporatingmonolithically interconnected cells, the substrate is typically not cutto define individual cells, though it may be cut to define a module. Aseparate wiring operation is also not performed, as cellinterconnections are formed during thin film deposition. Positioning ofindividual cells is also not necessary, though other module assemblyoperations may still be performed. In other embodiments, variousoperations may be performed in other sequences.

Regardless of the particular process employed, one or more of the modulefabrication operations and/or transfer there-between includes magneticmanipulation of the ferromagnetic module component, e.g., to facilitatesecuring, aligning, positioning aid/or transferring the ferromagneticmodule component.

Other Embodiments

In certain embodiments, electric-based manipulation and actuators may beused in addition to or instead of the magnetic-based methods andactuators described above, including conductive and inductive-basedmanipulation. For example, any of the above-described manipulators mayuse electrostatic force to manipulate a module component, e.g., that hasa charge build-up. In certain embodiments, electrostatic securingmechanisms, grabbing mechanisms, positioning or other mechanisms areprovided.

Although the foregoing invention has been described in some detail forpurposes of clarity of understanding, it will be apparent that certainchanges and modifications may be practiced within the scope of theinvention. It should be noted that there are many alternative ways ofimplementing both the processes and apparatuses of the presentinvention. Accordingly, the present embodiments are to be considered asillustrative and not restrictive, and the invention is not to be limitedto the details given herein.

1. A method of fabricating a thin film photovoltaic solar module,comprising: providing a plurality of thin film photovoltaic solar modulecomponents, at least one of said components being magnetic; providingprocessing apparatus for thin film photovoltaic solar modulefabrication, said apparatus comprising one or more magnetic actuators;and fabricating the thin film photovoltaic solar module by a processthat comprises magnetically manipulating the magnetic module componentswith the one or more magnetic actuators.
 2. The method of claim 1wherein at least one of said components is ferromagnetic.
 3. The methodof claim 1 wherein the thin film photovoltaic module components comprisephotovoltaic cells.
 4. The method of claim 3 wherein said thin filmphotovoltaic cells comprise a ferromagnetic substrate.
 5. The method ofclaim 4 wherein said ferromagnetic substrate is a stainless steel foil.6. The method of claim 4 wherein said ferromagnetic substrate comprisesseries 400 stainless steel.
 7. The method of claim 1 wherein the thinfilm photovoltaic solar module component comprises a substrate, saidsubstrate being magnetic.
 8. The method of claim 1 wherein one of theone or more magnetic actuators is a magnetic pallet.
 9. The method ofclaim 1 wherein one of the one or more magnetic actuators is a magneticcomponent grabber.
 10. The method of claim 1 wherein one of the one ormore magnetic actuators is an alignment mechanism.
 11. The method ofclaim 1 wherein fabricating the thin film photovoltaic solar modulecomprises transferring a partially fabricated thin film solar modulebetween a plurality of processing stations.
 12. The method of claim 11wherein transferring the partially fabricated thin film photovoltaicsolar module comprises securing at least some of the magnetic componentsby magnetic force.
 13. The method of claim 1 further comprising at leastone of the following operations: a coating operation to coat thin filmmaterials on a ferromagnetic substrate; one or more cutting operationsto cut the ferromagnetic substrate to form cells; a first laminatingoperation to laminate the cells; a positioning operation to position thelaminated cells on a module substrate; and a second laminating operationto laminate the module substrate having cells positioned thereon,wherein at least one of the operations comprises magnetic manipulationof the ferromagnetic substrate.
 14. A system for fabricating thin filmphotovoltaic solar modules having a plurality of thin film photovoltaicsolar module components, at least one of said components being magnetic,said system comprising: a plurality of processing stations forfabricating thin film photovoltaic solar modules; a plurality oftransport devices for transferring partially fabricated thin filmphotovoltaic solar modules between processing stations; and one or moremagnetic actuators, each actuator associated with a processing stationor a transfer device, and configured to magnetically manipulate themagnetic module components.
 15. The system of claim 14 wherein one ofthe one or more magnetic actuators comprises a magnetic pallet.
 16. Thesystem of claim 15 wherein said pallet comprises a planar pallet body; amagnetic sheet disposed on said planar pallet body; and a plurality ofspaced-apart substantially parallel magnetic elements disposed on saidmagnetic sheet.
 17. The system of claim 14 wherein one of the one ormore magnetic actuators comprises an aligning mechanism.
 18. The systemof claim 17 wherein the aligning mechanism comprises an alignment area,a fence, and a magnet movable between an aligning position closer to thefence and a second position further from the fence.
 19. The system ofclaim 17 wherein the aligning mechanism comprises an alignment area anda magnet positioned underneath the alignment area.
 20. The system ofclaim 14 wherein one of the one or more magnetic actuators is a magneticcomponent grabber.
 21. The system of claim 20 wherein the magneticcomponent grabber comprises a magnet movable between a grabbing andnon-grabbing position.
 22. The system of claim 14 wherein said magneticmanipulation of the magnetic components comprises securing a verticalroll of a ferromagnetic substrate.
 23. The system of claim 14 where oneor more of the magnetic actuators is a magnetic securing mechanism. 24.The system of claim 14 wherein the plurality of processing stationscomprises one or more of the following: a thin film web coating stationto deposit thin film materials on a stainless steel substrate, one ormore cutting stations to cut the stainless steel substrate to formcells, one or more laminating stations to laminate the cells andmodules; and a positioning station to position the laminated cells on amodule substrate.
 25. The system of claim 14 wherein the plurality oftransport devices comprises a conveyor belt.
 26. A method of fabricatinga module of thin film photovoltaic cells, said method comprising: acoating operation to coat thin film materials on a ferromagneticsubstrate; one or more cutting operations to cut the ferromagneticsubstrate to form cells or modules; a module assembly operation toassembly a module pre-laminate stack including a module substrate havingcells positioned thereon, bussing, diodes and module encapsulationmaterials; and a laminating operation to laminate the modulepre-laminate stack; wherein at least one of the operations or transferthere-between comprises magnetic manipulation of the ferromagneticsubstrate.
 27. The method of claim 26 further comprising a firstlaminating operation to laminate photovoltaic cells or cell-widthstrips.
 28. The method of claim 26 wherein the first laminatingoperation comprises providing a magnetic force to secure the cells orcell-width strips.
 29. The method of claim 26 further comprising apositioning operation to position photovoltaic cells on a modulesubstrate.
 30. The method of claim 29 wherein the positioning operationcomprises aligning a cell prior to positioning the cell on the module.31. The method of claim 30 wherein aligning the cell comprisesmagnetically actuating cell placement under a position sensing device.32. The method of claim 29 wherein the positioning operation comprisesproviding a pallet to support a partially fabricated thin filmphotovoltaic cell module, the pallet comprising a planar pallet body, amagnetic sheet disposed on the planar pallet body, and a plurality ofspaced-apart substantially parallel magnetic elements disposed on themagnetic sheet, wherein the magnetic sheet and the plurality ofspaced-apart substantially parallel magnetic elements provide a magneticfield; placing a plate on the pallet, and after placing the plate on thepallet, positioning a plurality of thin film photovoltaic cells on theplate.
 33. The method of claim 32 further comprising transporting thepallet having the plate and photovoltaic cells thereon for furtherprocessing; wherein the plurality of thin film photovoltaic cells areimmobilized on the plate by the magnetic field during transport.
 34. Themethod of claim 29 wherein the coating operation comprises providing amagnetic force to secure a roll of stainless steel while coating theroll with the thin film materials.
 35. The method of claim 34 whereinthe magnetic force secures a vertical roll of stainless steel.
 36. Athin film photovoltaic cell pallet to support a partially fabricatedthin film photovoltaic cell module, said pallet comprising a planarpallet body; a magnetic sheet disposed on said planar pallet body; and aplurality of spaced-apart substantially parallel magnetic elementsdisposed on said magnetic sheet.
 37. A magnetically actuated alignmentmechanism for a thin film photovoltaic solar module component,comprising: an alignment area configured to receive a thin filmphotovoltaic solar module component, said component being magnetic; afence adjacent to said alignment area; and a magnetic actuator movablein relation to the fence and configured to exert magnetic force on amagnetic module component in the alignment area to thereby bring it intoalignment with the fence.
 38. The magnetically actuated alignmentmechanism of claim 37 wherein said magnetic component is a photovoltaiccell comprising a ferromagnetic substrate.
 39. A magnetically actuatedalignment mechanism for a thin film photovoltaic solar module component,comprising: an alignment area configured to receive a thin filmphotovoltaic solar module component, said component being magnetic; afence adjacent to said alignment area; and a magnetic actuator movablein relation to the fence and configured to exert magnetic force on amagnetic module component in the alignment area to thereby bring it intoalignment with the fence.
 40. The magnetically actuated alignmentmechanism of claim 39 wherein said magnetic component is a photovoltaiccell comprising a ferromagnetic substrate.